Clutch Housing

Special tools and workshop equipment required

Punch VW 407
Drift T 10168
Thrust Piece T40008
Kukko Extractor 14.5-18.5 mm 21/2
Kukko Extractor 23.5-30 mm 21/4
Kukko Support 22/2

Fig 1: Identifying Clutch Housing Remove/Install Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bushing
- For the selector shaft with selector forks.
- Replace after removing.
- Removing, refer to Fig 2.
- Installing, refer to Fig 3.
Shaft for Reverse Gear Selector Fork
- Mount the reverse gear selector fork on the shaft, refer to Figure.
- The shaft cannot be removed with workshop tools.
- A new shaft must be installed when using a new clutch housing. Refer to Fig 6.
- Bearing on the selector shaft or the 5th and 6th gear selector fork, refer to Figure.
Needle Sleeve
- For the reverse shaft.
- Replace after removing.
- Removing, refer to Fig 4.
- Installing, refer to Fig 5.
Alignment Sleeve
- Quantity: 2
Clutch Housing
- When replacing: adjust the output shaft and differential, refer to ADJUSTMENT OVERVIEW .
Input Shaft Seal
- Removing and installing, refer to INPUT SHAFT SEAL .
  The seal can only be removed using the sleeve 30-21 when the transmission is disassembled.
Seal
- Replacing, refer to RIGHT FLANGE SHAFT AND SEAL .
Washer
- For the differential.
- Installed position: shoulder on inner diameter faces toward the seal, see item 7 in Fig 1.
Outer Race/Tapered Roller Bearing
- For the differential.
- Removing and installing, refer to DIFFERENTIAL .
- When replacing: adjust the differential, refer to DIFFERENTIAL, ADJUSTING .
Oil Deflector Ring
- Installed position: shoulder at the hole points toward the output shaft.
Outer Race/Tapered Roller Bearing
- Output shaft, 1st to 4th gears.
- Removing and installing, refer to OUTPUT SHAFT, 1ST TO 4TH GEARS .
- Adjust, if the output shaft for 1st to 4th gear is replaced. Refer to OUTPUT SHAFT, 1ST TO 4TH GEARS, ADJUSTING .
Outer Race/Tapered Roller Bearing
- Output shaft, 5th, 6th and reverse gears.
- Removing and installing, refer to OUTPUT SHAFT, 5TH, 6TH AND REVERSE GEARS .
- When replacing: adjust the output shaft for 5th/6th and reverse gear. Refer to OUTPUT SHAFT, 5TH, 6TH AND REVERSE GEARS, ADJUSTING .
Washer
- Output shaft, 5th, 6th and reverse gears.
- Always 0.65 mm thick.
Cylindrical Roller Bearing
- For the input shaft.
- Removing and installing, refer to INPUT SHAFT OVERVIEW .
Magnet
- Held in place by the housing joint surface.
Cap
- Not present on all clutch housings.

Removing the Selector Shaft Bushing

Fig 2: Identifying Kukko Tool Assembly To Pull Out Bearing Bushing For Selector Rod

Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Counter-support, for example, Kukko support 22/1

B - Internal puller 14.5 to 18.5 mm, for example, Kukko extractor 14.5-18.5 mm 21/2

Installing the Selector Shaft Bushing, to the Tool Stop

Fig 3: Identifying Bushing For Selector Rod Driven In To Tool Stop

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing the Needle Sleeve from the Clutch Housing

Fig 4: Identifying Kukko Support And Extractor To Pull Needle Bearing Off Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Counter-support, for example, Kukko support 22/2

B - Internal puller 23.5 to 30 mm, for example, Kukko extractor 23.5-30 mm 21/4

NOTE:

The needle sleeve will get damaged when it is removed and must be replaced.

Fig 5: Identifying Tool To Press-In Needle Bearing And Thrust Washer -B- To Needle Sleeve -A-

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing the Selector Shaft Bushing, to the Tool Stop

-- While installing, place the thrust washer -B- for the reverse shaft onto the needle sleeve.

Installing the Shaft for the Reverse Gear Selector Fork into the Clutch Housing

Fig 6: Identifying Tool To Press-In Axle For Reverse Gear Shift Fork To Clutch Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.